Heating Cable End Seal Using Cured Load-Supporting Layer
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Solution Overview
Problem
Existing methods for sealing the ends of heating cables used in liquid environments often result in cable distortion or leakage due to insufficient crimping forces, which can damage conductors or allow liquid ingress.
Innovation Solution
A method involving a curable sealant placed within a boot cavity, inserted into the cable end, cured to form a stable load-supporting layer, and secured with a crimping ring, using an assembly jig to manage the process and prevent sealant egress and radial expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crimping ring is used to secure the boot to the cable, then the boot is firmly attached and sealing is improved, but the cable body may be damaged and conductors may be distorted
Solution Approach 1:
A curable sealant is inserted into the boot cavity before the cable is inserted. The sealant is then cured to form a stable load-supporting layer that can withstand crimping forces. This preliminary action prepares the boot-cable assembly to receive the crimping ring without damaging the cable, as the cured sealant absorbs and distributes the crimping forces.
Solution Approach 2:
The curable sealant acts as an intermediary material between the boot and the cable. When the crimping ring is applied, the sealant layer serves as a cushioning intermediary that distributes the mechanical stress, preventing direct transmission of crimping forces to the cable conductors while maintaining the mechanical bond between boot and cable.
2Reliability
If the boot is crimped tightly to ensure sealing, then liquid ingress is prevented, but the cable may distort and conductors may be damaged
Solution Approach 1:
The curable sealant is placed in the boot cavity and cured before crimping. This creates a stable load-supporting layer that maintains the boot's shape and position during crimping, preventing cable distortion while ensuring tight sealing against liquid ingress.
Solution Approach 2:
The cured sealant layer serves as a pre-established cushioning element between the crimping ring and the cable. This beforehand cushioning protects the cable geometry from deformation during the crimping process while still allowing sufficient compression for effective sealing.
3Reliability
If the cable is forced into the boot with sealant, then sealing is achieved, but curable sealant may escape from the boot
Solution Approach 1:
The curable sealant is inserted into the boot cavity and cured before the cable is forced into the boot. This preliminary curing creates a stable load-supporting layer that contains the sealant within the boot, preventing escape during cable insertion while ensuring proper sealing.
Solution Approach 2:
The sealant transitions from a liquid or paste state (when inserted) to a solid cured state (after curing). This parameter change in physical state allows the sealant to be contained within the boot during cable insertion, preventing loss, while still providing effective sealing when the cable is forced into place.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively seals the heating cable end, withstanding external pressures without damaging the conductors and preventing liquid leakage, while allowing for easy boot removal for inspection or repair.
Implementation Method 1
curing the curable sealant to provide a stable load supporting layer of sealant within the cable
Implementation Method 2
applying a crimping ring to the boot in the area of the load supporting layer to secure the boot to the cable
Implementation Method 3
Electrical current passing through the conductors produces a heating effect which can be transmitted to surrounding environments
Data Source
AI summary
A method of forming an end seal on a cable. The method includes placing a curable sealant in a cavity formed in a boot, inserting an end of the cable in to the cavity with the boot extending about the exterior of the cable, forcing the cable in to the curable sealant while inhibiting the egress of curable sealant from the boot to force the curable sealant along the interior of the cable, curing the curable sealant to provide a stable load supporting layer of sealant within the cable, and applying a crimping ring to the boot in the area of the load supporting layer to secure the boot to the cable.